Process for welding diminutive objects



Sept. 4, 1962 J. B. JONES ET AL l3,052,020

PROCESS FOR WELDING DIMINUTIVE OBJECTS 4 Sheets-Sheet l Criginal FiledJune 3, 1958 Sept. 4, 1962 J. B. JONES ETAL PROCESS FOR WELDINGDIMINUTIVE OBJECTS Original Filed June 5, 1958 Fig. 3

4 Sheets-Sheet 2 INVENTORS JAMES BYRON JONES WILLIAM C. ELMORE CARMINEF. DE PRISCO BYCPJAHHSLM ATTORNEY Sept. 4, 1962 J. B. JONES ET A1.A3,052,020

PROCESS FOR WELDING DIMINUTIVE OBJECTS Original Filed June 5, 1958 4Sheets-Sheet 3 ATTORNEY Sept. 4, 1962 .1. B. JONES ET AL 3,052,020

PROCESS FOR WELDING DIMINUTIVE OBJECTS Original Filed June 3, 1958 4Sheets-Sheet 4 Fig.

MES BYROJSVEQRS JA WILLIAM C. ELMORE CARMINE F. DEPRISGO BYCLJCQM umATTORNEY 3,052,020 PROCESS FOR WELDING DIMINU'IIVE BIEC'IS James ByronBones, West Chester, Wiliiarn C. Eimore, Media, and Carmine F. DePrisco, West Chester, Pa., assignors, by mesne assignments, to SonobondCorporation, West Chester, Pa., a corporation of Pennsylvania Originalapplication lune 3, 1958, Ser. No. 739,505. Di-

vided and this application Nov. 29, 1960, Ser. No.

4 Claims. (Cl. 29-470.I)

The present invention relates to a process for welding diminutiveobjects. More particularly, the present invention relates to a vibratoryprocess for welding a metal object whose largest cross-sectionaldimension is of the order of 0.075 inch to another metal object of thesame, smaller, or larger size. In particular, the present invention hasprime utility for the welding of line wires to each other or to otherobjects, as in the case of igniter assemblies or explosives, iilamentsfor light bulbs, diminutive thermocouples, foils, and articles ofjewelry.

Attempts to weld wires or thin foils are often unsatisfactory for anumber of reasons. Thus, in many cases the high energy and heating ofconventional welding damages the extremely thin metal or the smallobject. Experience has shown that not only are such weldments frequentlyunsightly, but that they often require considerale cleaning or dressingbefore the materials can be plated or otherwise nished. Moreover,contemporary welding methods joining diminutive objects commonly producea degree of sputter or spetter of melted metal or oxide, which amountsto extruded or exploded material, as well as often giving ofi gaseousmaterial. In particular, in the case of precision assemblies such astransistors and vacuum-type elements, objects which are to function forvery long times without attention especially in high-purity atmospheres,the presence of such impurities leads to early malfunction.

An electrical igniter assembly comprises two electrical conductorsmutually connected together esssentially at their ends by a ine filamentwhich, when electric current is introduced, instantly heats toincandescence and disintegrates, said heating and/ or disintegratinginitiating an explosive train. Experience with production methods forthe resistance welding of these objects has demonstrated that frequentlythe resultant igniter assemblies are of inconsistent quality. In manycases in commercial igniter assemblies, the variations in wire strengthand resistance measurements of the assemblies were serious enough togive rise to potential malfunctioning of the device.

In particular, where commercial applications demand the welding togetherof diminutive metal members which are contoured, dii'licult problems areencountered with existing Welders and processes.

This invention has as an object the provision of a process forvibratorily welding together a plurality of diminutive objects.

This invention has another object the provision of a process forvibratorily welding contoured diminutive objects.

For the purpose of illustrating the invention there is shown in thedrawings forms which are presently preferred; it being understood,however, that this invention is not limited to the precise arrangementand instrumentalities Shown.

Referring to the drawings wherein like reference characters refer tolike parts:

FIGURE l is a side elevation of one embodiment of the vibratory welderof the present invention.

FIGURE 2 is a section taken on line 2 2 of FIGURE l.

Etates Eatent FIGURE 3 is a plan View of the embodiment of FIG- URE 1.

FIGURE 4 is an elevational view of the welding tip of the embodiment ofFIGURE l.

FIGURE 5 is a view of the welding tip of the embodiment of FIGURE ltaken from the plan view of FIG- URE. 3.

FIGURE 6 is a front elevational view of the welding tip of theembodiment of FIGURE l.

FIGURE 7 is a side elevational view of the reiiector tip or anvil of theembodiment of FIGURE l.

FIGURE 8 is a View of the reflector tip or anvil of the embodiment ofFIGURE l in the plane of FIGURE 3.

FIGURE 9 is a front elevational view of the reflector or anvil of theembodiment of FIGURE l.

FIGURE l0 is an elevational view of another embodiment of the presentinvention with part of the housing cut away to reveal the internalStructure of such embodiment.

FIGURE ll is a plan sectional view from above of the magnetostrictivetransducer, sonotrode, mount, and anvil of the embodiment of FIGURE 10.

FIGURE l2 is a View taken on line 12-12 of FIG- URE l0.

Referring to the drawings and initially to FIGURES l through 9inclusive, the Vibratory Welder shown therein is designated generally as20. The Welder 20 includes a stationary fixed welding tip 22 and areciprocally movable reflector tip or anvil tip 24. As will be morefully explained below, the workpieces to be welded are disposedintermediate the juxtaposed faces of the welding tip 22 and thereilector tip 24.

rThe welding tip 22 is secured to the sonotrode 26 at the free endthereof. The sonotrode 26 comprises a cylindrical rod which is anacoustical reed of metal and which is supported by the mass member Z8which is xedly secured in place in the framework as by means of bolts30. The mass member 2S in this case comprises a pair of contoured blocks32 and 34 which may be bolted together by means of bolts 36.

The reed-like sonotrode 26 is vibrated in iiexure by means or thetransducer 38 and the coupling member 40, the latter comprising atapered or otherwise contoured metallic element brazed, soldered orwelded or otherwise secured to transducer 38 and which can encircle andbe joined to an intermediate portion of `sonotrode 26, being brazed orwelded thereto.

Transducer 3S comprises a laminated core of nickel or othermagnetostrictive metallic material, and may have a rectangularly-shapedopening 42 in its center portion. A polarizing coil 44 and an excitationcoil 46 may be wound through the opening 42 Within transducer 38. Uponvariations of the magnetic eld strength of the excitation coil 46, therewill be produced concomitant variations in the dimension of thetransducer 33, provided the polarizing coil 44 is charged at a suitablelevel with D.C. current, and it will be appreciated by those skilled inthe art that the frequency of the aforesaid variations, namely theexpansion and/ or contraction of the magnetostrictive transducer will beequal to the frequency of the alternating electric current ilowing inthe excitation coil.

Suitable bracing and cushioning posts 43 disposed on either side oftransducer 38 and carried by the housing 50 are provided to secure thetransducer 38 in position.

In place of the transducer 3S shown in the drawings, othermagnetostrictive materials may be utilized such as the alloy Z-V`Permendur (an iron-cobalt alloy), a nickeliron alloy, or Alfenol (analuminum-iron alloy), properly dimensioned to insure axial resonancewith the frequency of the alternating current applied thereto, so as tocause it to decrease `or increase in length according to its coefficientor magnetostriction. Transducers of the aforesaid type presentlyconstitute a preferred embodiment for operation at frequencies of up toabout 75,000 cycles per second, although they may be used at higherfrequencies. As the frequency range within which such metal transducersare presently preferred is the preferred frequency range of thisinvention, the aforesaid metal magnetostrictive transducers comprise thepreferred transducers for the Welders `of the present invention.However, in place of the aforesaid metallic magnetostrictive materials,the transducer may comprise almost any material which has good physicalproperties and which changes its physical dimensions under the influenceof electrical potential or electric current. Thus, it may comprise apiezoelectric material, such as quartz crystals, or an electrostrictivematerial such as barium titanate, lead zirconate, etc. Such materialspresently are preferably used at high frequency operations, as atfrequencies above about 75,000 cycles per second, although they can beused at lower frequencies. The transducer may also consist offerroelectric materials or an electromagnetic device, such as that whichactuates a radio loudspeaker.

The housing 50 also includes a blower 52 for cooling the transducer 3S.

The reector tip 24 is carried on reciprocally movable carriage 54, whoseconstruction is shown particularly in FIGURES 2 and 3.

The carriage 54 is iixedly secured by bolts 56 to the element 58 whichhas the cross-section of an inverted omega. Runners 60 are secured bybolt means 62 at either side of the inverted omega-shaped element 58.

Each of the runners 60 are provided with pillows or blocks 64 secured bysetscrews 66.

The carriage 54 rides on the ways 68, with the pillows 64 slidablyengaging juxtaposed surfaces of such ways 68. The ways 68 are secured tothe housing 50 by means of bolts 7 0.

A xedly secured thrust housing 72 is provided on the opposite end ofhousing 50 from mass member 28'. Thus, the -thrust housing 72 may besecured by means of bolts 74 to the housing '50.

The thrust housing 72 is provided with a cylindrical recess 76 withinwhich is reciprocally Ireceived the piston 78. The end 80 of the pistonrod of piston 78 is threaded and threadably secured Within a matingsocket 82 in thrust housing 72.

A spring 84 is seated on the free face of the piston 78 and on a springseat 36 at the rear of carriage 54.

The spring V84 urges the `carriage 54 which carries the reflector tip 24towards the welding tip 22 carried on the xedly secured sonotrode 26.

A retraction arm 88 is secured to carriage 54, the retraction arm 88passing through the passageway 90 within thrust housing 72. The threadedend 92 of retraction arm 88 may be secured to suitable retraction means,such as to a hydraulic cylinders piston, or the like, or retraction arm88 may be manually operated.

Movement of retraction arm 86 away from mass member 28 withdrawscarriage 54 from the welding tip 22.

Adjustment of the position of the piston 78 within the cylindricalrecess 76 permits the spring pressure exerted by the spring 84 to bevaried to conform to a predetermined value. In order to effect thewithdrawal of the carriage 54, the pull to be exercised on theretraction arm 88 must exceed the pressure exerted by the spring 84.

The welding tip 22 and the reflector tip 24 which are shown -in theillustrated embodiment of the vibratory welder are intended for thepreparation of an igniter assembly in which a wire, as `for example a0.00156-inchdiameter platinum-tungsten wire, is secured to a pair ofposts, as for example a pair of 0.025-inch-diameter copper posts. It isto be understood that the specific construction of the welding tip andreflector tip set forth below, While preferred for the production of anigniter assembly of the type heretofore referred to, may be varieddepending of tapered section.

il upon the specific assembly which the user intends to manufacture.

Referring now particularlyto FIGURES 4 through 9, there is shown thereina welding tip 22 and a reflector tip 24 having prime utility, asheretofore noted, for the formation of an igniter assembly in which avery fine wire, such as a 0.00l56-inch diameter platinum-tungsten wire,is welded onto two posts, specifically being welded to two spaced postsat right angles to the longitudinal axis of each of the posts and on thesame side of each of the posts, with suitable posts includnig a0.025-inch diameter copper post or a 0.025-inch diameter tinned copperposts, or iron posts.

The welding tip 22 (see FIGURES 4 through 6) cornprises a Sculpturedelement whose front face comprises the generally flat surface 94 and thepair of spaced forwardly projecting engagement members 96 whosefrontmost surfaces are likewise fiat.

The reflector tip 24 (see FIGURES 7 through 9) has a fiat front surface98 provided with a pair of spaced semicircular grooves 100', which asparticularly shown in FIGURE 3 are disposed when the welding tip 22 andreflector tip 24 are mounted on sonotrode 26 and carriage 54respectively in juxtaposition to the forwardmost faces of the engagementmembers 96.

The aforesaid design of the welding tip 22 and the reector tip 24permits assemblage of igniter assemblies to be made individually or inthe following fashion:

The platinum-tungsten wire may be led by suitable guide means (notshown), such as guide blocks having suitable shims for regulating theheight of the platinumtungsten wire, across the ilat surfaces of theengagement members 96 at a suitable height thereon, while the posts maybe fed, either in post assemblies in which case intermittent operationis necessary to effect removal of the post assembly and replacementthereof after each weldment, or as continuous strands through thegrooves 100. Thus, the posts may be fed through the grooves 100vertically upwardly. After each weld, accomplished in accordance withthe process of our invention described below, the platinum-tungsten wiremay be cut permitting the posts to be drawn upwardly. After the postshave been drawn upwardly a predetermined distance, a new weld isaccomplished, the platinum-tungsten wire meanwhile having been fedacross the faces of the engagement members 96.

Referring now to the embodiment of our invention shown in FIGURES l0through l2, there is shown therein a vibratory Welder E02 having awelding tip 104 and a reflector anvil face 106. The welding tip 104 inthis case comprises an octagonally-shaped member, whose lowermost faceis provided with engagement members similar to the engagement members 96of welding tip 22. The reflector anvil face N6 is provided with groovessimilar to the grooves 100 of reflector tip 24.

Welding tip 104 is carried on the sonotrode 108 which comprises acylindrical rod portion metal-to-rnetal bonded in end-to-end contactwith transducer 110. The sonotrode 10S may comprise a cylindricalportion 109 and a tapered portion 111i `whose taper may ibut need notnecessarily, satisfy the squation set forth at page 163 of PiezoelectricCrystals and Ultrasonics, by Warren P. Mason, published in 1950 by VanNostrand Company, namely a curved coupling member whose l'taper is anexponential function of the length and satisfies the relation:

where S equals the original area, S0 equals the reduced area, T equalsthe taper constant, and l equals the length The total length of thesonotrode 108 should be an integral number of half wavelengths of thetransducers frequency according to the material used, so that the jointbetween the transducer 110 and the sonotrode 108 will come at a loop ofthe wave motion and will not be appreciably strained.

The sonotrode 108 and transducer 110 are supported by means of a supportmount, which is described in United States patent application Serial No.517,599, filed June 23, 1955, in the name of William C. Elmore, entitledVibratory Device, now abandoned, and in o0- pending United States patentapplication Serial No. 679,- 041, tiled August 19, 1957, in the name ofWilliam C. Elmore, now patent 2,891,180, entitled Support for VibratoryDevices. The support mount comprises a cylindrical metal shell, such asthe cylindrical steel shell 112, or a resonant-in-length shell of othersuitable rnaterial, said shell having a length of at least a singleonehalf wavelength according to the metal used at the applied frequency.Shell 112 may have a length equal to a multiple number of one-halfwavelengths. In the illustrated embodiment shell 112 has a length equal'to a single one-half wavelength. Shell 112 surrounds the cylindricalrod portion 109 of sonotrode 108 Vand is concentric therewith and joinedthereto at the shells end 114 by appropriate means, as by welding,brazing, or soldering. The free end 116 of shell 112 is free from anyattachment and, accordingly, when the system is vibrating a true nodewill develop in the cylindrical shell 112 at the region of theattachment means 118 which is positioned approximately midway (where theShell has a length, as does the subject shell of a single one-halfwavelength) of ends 114 and 116, or namely one-quarter wavelengthdistant from free end 116 of cylindrical shell 112.

The attachment means 118 comprises a radially extending flange or lipxedly secured intermediate the transverse plate 120 and the retentionannulus 122, bolts 124 being utilized to engage the transverse plate 120and the retention annulus 122. As can be seen from FIGURE 11, thetransverse plate 120 and the retention annulus 122 may be rabbeted toprovide for aligning securement of attachment means 118.

The transverse plate 120 is carried intermediate a pair of parallelpivot arms 128 which are pivoted about pivot 130 which is suspendedintermediate the brackets 132 carried bythe housing 134.

yThe end of each of the pivot arms 128 remote from the pivoted end issecured by pivots 136 to yoke 138.

-The yoke 138 is secured to the piston rod 140 of the piston of -aircylinder 142.

The air cylinder 142 is pivotably secured by means of pivot 144intermediate the pivot straps 146 which are carried on the base ofhousing 134.

A blower 143 is carried on the base of housing 134 for cooling thelaminations forming the nickel stack of magnetostrictive transducer 110.

An air conduit 150 for delivering compressed air to Welder 102 isprovided at the rear of housing 134. The conduit 150 enters housing 134and passes through air pressure regulator 152 which may be of anysuitable construction for regulating the air pressure to a desiredlevel.

'From pressure regulator 152 the air conduit 150 extends to thesolenoid-operated air valve 154. The solenoid-operated air valve 154 isactuated directly by the user, as Iby means of a foot switch (not shown)connected to the `solenoid-operated air valve 154 through the conduit156i.

The air-discharge conduit 158 from solenoid-operated air valve 154 isbifurcated by means of T 160.

`One of the air conduits 1611 from T 160 extends to pressure switch 162.The pressure switch 162 may comprise any suitable yswitch of which thereare -a number available commercially which closes an electrical circuitresponsive to a predetermined air pressure. Pres-sure switch 162 isappropriately connected into excitation coil 166 of transducer 110 andto the high-frequency alternating current power source which suppliesexcitation 6 coil 166 of transducer 1111 and controls the flow ofelectrical current to the transducer incident to the achievement of apre-set air pressure.

iThe other air conduit 163 from T 161) is bifuroated by T 170 into rigidconduit 172 which is connected to the `gauge 174, and to the flexibleair conduit 176 which is connected to the air cylinder 142. The use of aflexible conduit 176 permits the air cylinder 142 to be in communicationwith T 170 notwithstanding rthe pivotation of the air cylinder 142.

The housing 134 provides a xed support or base `for the reflector anvil178 which supports the reflector tip 106.

The normal position of the embodiment shown in FIGURES l0 through 12 iswith the welding tip 104 urged against the reflector tip 1116. Theclamping force between the welding tip 104 and the reflector tip 106 isachieved by the downward movement of the piston rod of air cylinder 142.

The air pressure regulator 152 m-ay be set manually to deliver anydesired degree of air pressure, permitting rthe clamping force to bechanged at will. The pressure switch 162 may be set so that thetransducer 110 is energized only when a predetermined clamping forcelevel, as indicated lby the air pressure ygauge 174, is reached.

The solenoid valve 154 which controls the flow of -air to the pressureswitch 162, gauge 174, and air cylinder 142, may be actuated by a footswitch, as heretofore indicated, or alternatively in assembly line unitsmay beactuated by suitable automatic control means.

The process of the present invention in which a diminu-v tive metalobject whose largest cross-sectional `dimension is of the order of0.075-inch is welded to the same size, smaller, or larger metal object(by larger metal object is meant to include massive metal objects ofconsiderable or unlimited size) is effected as follows:

=T he vibratory welding frequency which may be used in the process ofthe present invention is not critical but may be varied wit-hin a very'broad range such as 400 to 300,000 cycles per second or more. Theoptimum operating frequency for diminutive objects according to theprocess of the present invention lies between about 10,000 and 100,000cycles per second. This optimum range of operating frequencies may bereadily achieved by transducer elements of known design, which arecapable of `generating vibratory energy of high intensity.

Clamping forces to be used in the process of the present inventionshould be regulated wit-hin the range of two to seventy-tive pounds.Preferably, the clamping force should be maintained within the range oftwenty to fty pounds. The minimal clamping force should be a clampingforce within the aforesaid range which maintains the metals being weldedin regulated alignment and firm contact, eg. contacting each other sothat the weld may be effected by the application of vibratory energy.

Welding in accordance with the present invention should be achievedwithin the time period of 0.005 to 1.3 seconds, and preferably withinthe time period of 0.005 to 0.8 second.

The power level 4for the welding process of the present invention shouldbe maintained Within the range of 5 watts to 400 watts, and preferablybetween 15 and 250 Watts.

Welding in accordance with the process of the present invention is inmany instances initiated at room temperatures or ambient temperatureswithout the application of heat.1 lf desired, welding in accordance withthe process of the present invention may also be initiated at elevatedtemperatures below the fusion temperature (melting point or solidustemperature of any of the pieces lThe weldrnent may be Warm to the touchafter the weld due to the application of the vibratory energy.

being bonded) .2 Thus, heating the metals to be welded prior to and/ orduring Welding to a temperature below their fusion temperature may, insome cases, facilitate the ease of welding and lower the powerrequirements and/ or time requisite to achieve welding.

The welding process of the present invention is applicable to theformation of both spot welds and seam welds.

The Welding process of our invention may be applied to a wide variety ofmeals, examples of which include: platinum-tungsten alloy to copper;platinum-tungsten alloy to tinned copper; platinum-tungsten alloy toiron; and many other similar and dissimilar combinations.

The welding of most metals can be eifected in accordance with theprocess of our invention in the ambient atmosphere. However, the processof our invention comprehends welding in highly evacuated atmospheres, orin selected atmospheres, such as atmospheres comprising an inert gas.Furthermore, while the welding process of our invention may be eectedwith metals, such as aluminum, without the extensive precleaningrequired to eiiect satisfactory welding by other methods, a degree ofprecleaning and surface treatment may prove advantageous in the weldingof many metals. It is desirable prior to effecting welding in accordancewith the present invention to remove surface contaminants, such ashydrocarbon or other lubricants and the like.

In the following examples in which in each case the welding wascommenced at room temperature fair to excellent welds were made usingthe following post wire materials and bridge wires (the examples aredirected to the `formation of igniter assemblies) at a frequency of15,000 cycles per second and under the following conditions:

Example l A platinum-tungsten wire having a diameter of about0.0015-inch was welded to a bare copper wire having a diameter of about0.025-inch which had been folded back upon itself with theplatinum-tungsten wire disposed between the folded backv portions. Theclamping force used was between twenty-one and thirty pounds, the weldtime was between 0.1 :and 1.0 second, and the effective R-F power wasbetween 160 to 200 watts. A fair weld was achieved.

Example Il The weld of Example I was repeated except that in place ofbare copper wire a tinned 0.025-inch copper wire was substituted and theclamping force was maintained at thirty pounds. A fair weld wasachieved.

Example III The weld of Example I was repeated except that in place ofthe bare copper wire a bare 0.006-inch iron wire was substituted, andthe weld time Was maintained at 1.3 seconds, the clamping force atthirty pounds, and the effective RJF power at 150 watts. A fair weld wasobtained.

Example IV A platinum-tungsten wire having a diameter of about0.0015-inch was welded across a bare copper post having la diameter ofabout 0.025-inch using a clamping force of from fifteen to thirtypounds, a weld time of from 0.5 to 1.3 seconds, and an effective R-Fpower of 100 to 150 watts. Excellent welds were obtained.

Example V The weld of Example IV was repeated except that in 2 Thetemperatures to which the foregoing statements refer are those which canbe measured by burying diminutive thermocouples (where possible) in theWeld zone prior to Welding, as Well as the temperatures which can beestimated or approximated from a metallographic examination of acrosssection of a vibratory Weld in the ordinary magmcatlon range of upto about 500 diameters.

8 place of the bare copper wire, a tinned copper wire having a diameterof 0.025-inch was substituted. Very good welds were obtained.

Example VI The procedure of Example IV was repeated except that in placeof the platinum-tungsten wire a 0.004-inch-thick platinum-tungstenribbon was substituted, and the weld time was maintained between 1.0 and1.3 seconds, the clamping force at thirty pounds, and the effective R-Fpower at to 150 watts. A good weld was obtained.

Example VII The weld of Example IV was repeated except that in place ofthe :bare copper post of 0.025-inch a bare low carbon steel wire havinga diameter of 0.25-inch was substituted, and the weld time wasmaintained between 1.0 and 1.3 seconds, the clamping force at thirtypounds, and the effective R-F power at watts. A good weld was obtained.

Example VIII Several hundred welds were made using an approximately0.0015-inch platinum-tungsten wire (one percent elongation) or a similarwire (four percent elongation) to determine the optimum weldingconditions in terms of producing weld strength consistency. summarizingthe numerous examples, it was determined that the optimum conditionscomprise a power level of about 200 to 250 R-F watts, a clamping load ofabout forty pounds, and an exposure time of between 0.5 to 0.8 second.No differences were noted between specimens involving lowductility wireor those involving high-ductility wire, and welding to bare copper postswas achieved as readily as to tinned posts.

This application is a division of our copending application Serial No.739,505, tiled on June 3, 1958, for Vibratory Welder for DiminutiveObjects and Process for Welding Diminutive Objects.

The present invention may be embodied in other specic forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

We claim:

1. A non-fusion method for welding the metal members together comprisingplacing a to-be-welded metal member having its largest transversedimension less than about .075 inch within a recess in an anvil, placinga second metal member in intimate contact with said rst mentioned metalmember at the intended weld zone, applying a force of between 2 and 75pounds to the metal members while the metal members are held betweensaid anvil and a rib on a vibrating element, with said rib beingjuxtaposed and substantially parallel to said recess, applying saidforce in a direction to hold the contacting to-be-welded surfaces of themetal members in intimate contact at the intended weld zone and tocouple mechanical vibratory energy into said zone, and introducingthrough said vibrating element contacting the second metal memberadjacent the weld Zone mechanical vibration having a frequency ofbetween about 59 and 300,000 cycles per second, said mechanicalvibration comprising a vibration component in a direction substantiallyperpendicular to the direction of applied force, and with such componentbeing of an energy level suflicient to weld the metal members to eachother.

2. A non-fushion method in accordance with claim l includingreciprocating said anvil in a direction substantially parallel to thelongitudinal axis of said vibrating element after said metal members arewelded to each other.

3. A non-fusion method as set forth in claim 1 in which the time periodfor said mechanical vibration is between stantially parallel to a secondri-b on said vibrating ele- 0.005 to 0.8 second. ment.

4. A DOH-fuSiOIl method in accordance Claim 1 References in the le ofthis patent wherein said second metal member is simultaneously welded tosaid rst member and a third member, with 5 UNITED STATES PATENTS saidthird member being disposed in .a recess on said anvil 2,707,823 SowterMay 10, 1955 and said last-mentioned recess being juxtaposed and sub-2,985,954 Jones et a1 May 30, 1961

